Conical Filter Pleat Spacing for Uniform Flow Distribution
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Solution Overview
Problem
Conical filter elements with fixed pleat counts suffer from uneven flow distribution, increased pressure drop, and suboptimal particle capture due to varying pleat spacing along the axial length, leading to inefficiencies in filtration and coalescing processes.
Innovation Solution
A pleated filter media design with adjustable and uniform pleat spacing along the axial length of a conical shape, allowing for optimized pleat packing and flow distribution, achieved by cutting the media in a pattern that forms a conical shape when rolled into a tube, ensuring consistent pleat spacing and improved fluid flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a fixed number of pleats is used around the circumference of a conical filter along its axial length, then the filter structure is simple to manufacture, but the flow distribution through the filter media becomes uneven and pressure drop increases
Solution Approach 1:
The patent applies local quality by varying the pleat spacing along the axial length of the conical filter. Different sections of the filter have different numbers of pleats per unit circumference length, with the smaller diameter end having more pleats and the larger diameter end having fewer pleats. This non-uniform distribution optimizes flow distribution across different sections of the filter media, reducing pressure drop while maintaining manufacturing feasibility through a systematic pleat counting method.
2Area of stationary object
If pleats are densely packed at the top of the conical filter to maximize filtration area, then the usable surface area increases, but the pressure drop across the filter increases and flow distribution becomes uneven
Solution Approach 1:
The patent optimizes the balance between filtration area and pressure drop by implementing local quality variations in pleat density. The smaller diameter end of the conical filter has higher pleat density to maximize filtration area in that region, while the larger diameter end has lower pleat density to maintain acceptable pressure drop and flow distribution. This graduated pleat counting method ensures optimal utilization of filtration surface area while preventing excessive pressure drop.
3Productivity
If the pleat spacing varies along the axial length of the conical filter, then the flow distribution improves, but the manufacturing precision requirements increase
Solution Approach 1:
The patent applies segmentation by dividing the conical filter into discrete axial sections, each with a specific number of pleats counted from a reference point. This systematic approach segments the pleat formation process into manageable units, where the number of pleats is incrementally increased or decreased at predetermined axial intervals. This segmentation method simplifies the manufacturing process while achieving the desired non-uniform pleat distribution for optimal flow characteristics.
4Reliability
If a conical filter configuration is used to reduce annular velocity and re-entrainment, then particle capture efficiency improves, but the pleat packing becomes suboptimal with fixed pleat counts
Solution Approach 1:
The patent enhances particle capture efficiency in the conical filter by applying local quality principles to pleat distribution. The smaller diameter end, where annular velocity is naturally lower and particle deposition is more effective, has higher pleat density to maximize capture efficiency. The larger diameter end, where annular velocity is higher, has lower pleat density to maintain appropriate flow characteristics. This optimized pleat counting method fully utilizes the conical configuration's inherent flow distribution benefits.
Data Source
AI summary
A frusto-conical filter includes at least one layer of a filtering material, wherein one or more layers of the at least one layer of a filtering material comprises a plurality of pleats. Each of the pleats has a center axis which essentially maintains a constant distance from the center axis of its adjoining pleats. The media filter has a first end and a second end, the second end being spaced apart from the first end, and one of the first and second ends is larger than the other of the first and second ends. A method of making this media involves cutting out a frusto-conical section from a generically shaped media and aligning it in such a way as to maintain the constant distance of the pleats from the adjacent pleats.